Pallet bag gathering apparatus and process for use

ABSTRACT

Pallet bag gathering apparatus to gather pallet bags for use in an automated pallet bag packaging system, preferably for the packaging of fruits or vegetables. The pallet bag gathering apparatus may be automated, semi-automated or manual in nature.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/698,796, filed on Jul. 16, 2018 and relates to U.S. application Ser. No. 15/604,629, filed May 24, 2017, U.S. Provisional Application No. 62/340,966, filed May 24, 2016, and the following commonly assigned applications, including application Ser. No. 13/368,216, filed Feb. 7, 2012. Application Ser. No. 13/368,216, filed Feb. 7, 2012 is a continuation of Ser. No. 09/858,190, filed May 15, 2001, now U.S. Pat. No. 8,110,232. Ser. No. 09/858,190 is also related to claims priority under 37 CFR 1.78(a)(5) from Provisional Application Ser. No. 60/325,762, filed May 26, 2000, which resulted from the conversion of application Ser. No. 09/580,379, into a provisional application under 37 CFR 1.53(c)(2). This application is also related to (1) application Ser. No. 09/989,682, filed Nov. 20, 2001, now U.S. Pat. No. 7,601,374, which is a continuation-in-part of Ser. No. 09/858,190, (2) application Ser. No. 12/553,852 filed Sep. 3, 2009, now U.S. Pat. No. 8,092,848, which is a divisional of Ser. No. 09/989,682, and co-filed applications from U.S. Provisional Patent Application Nos. 62/698,908, 62/698,923, and 62/701,364. The entire disclosure of each of those patents and applications is incorporated herein by reference for all purposes.

This invention relates to the packaging of respiring and non-respiring biological materials, particularly various berries. This invention is useful in packaging any and all fresh fruit and vegetables. In particular, it is useful in increasing the speed of the packing operation, reduces worker fatigue, increases reproducibility, decreases errors, and allows for automation of the packaging process for a variety of pallet sized packaging of biological materials.

Respiring and non-respiring biological materials, e.g. fruits and vegetables, consume oxygen (O₂) and produce carbon dioxide (CO₂) at rates which depend upon the stage of their development, the atmosphere surrounding them and the temperature. In modified atmosphere packaging (MAP), the objective is to produce a desired atmosphere around respiring and non-respiring materials by placing them in a sealed container whose permeability to O₂ and CO₂ and CO₂ is correlated with (i) the partial pressures of O₂ and CO₂ in the air outside the package, and (ii) the temperature, to produce a desired atmosphere within the container and (iii) the gas permeation properties of the chosen package materials and components. In many cases, the container includes an atmosphere control member having a high permeability to O₂ and CO₂. In controlled atmosphere packaging (CAP), the objective is to produce a desired atmosphere around respiring and non-respiring materials by displacing some or all of the air within a container by one or more gases, e.g. nitrogen, O₂, CO₂ and ethylene, in desired proportions. Reference may be made, for example, to U.S. Pat. No. 3,360,380 (Bedrosian), U.S. Pat. No. 3,450,542 (Badran), U.S. Pat. No. 3,450,544 (Badran et al.), U.S. Pat. No. 3,798,333 (Cummin et al), U.S. Pat. No. 3,924,010 (Erb), U.S. Pat. No. 4,003,728 (Rath), U.S. Pat. No. 4,734,324 (Hill), U.S. Pat. No. 4,779,524 (Wade), U.S. Pat. No. 4,830,863 (Jones), U.S. Pat. No. 4,842,875 (Anderson), U.S. Pat. No. 4,879,078 (Antoon), U.S. Pat. No. 4,910,032 (Antoon), U.S. Pat. No. 4,923,703 (Antoon), U.S. Pat. No. 4,987,745 (Harris), U.S. Pat. No. 5,041,290 (Wallace et al.) U.S. Pat. No. 5,045,331 (Antoon), U.S. Pat. No. 5,063,753 (Woodruff), U.S. Pat. No. 5,160,768 (Antoon), U.S. Pat. No. 5,254,354 (Stewart), U.S. Pat. No. 5,333,394 (Herdeman), U.S. Pat. No. 5,433,335 (Raudalus et al.), U.S. Pat. No. 5,460,841 (Herdeman), U.S. Pat. No. 5,556,658 (Raudalus et al.), U.S. Pat. No. 5,658,607 (Herdeman), U.S. Pat. No. 6,013,293 (De Moor) and U.S. Pat. No. 6,376,032 (Clarke et al), International Publication Nos. WO 94/12040 (Fresh Western) and WO 00/04787 (Landec), and European Patent Applications Nos. 0,351,115 and 0,351,116 (Courtaulds). The disclosure of each of these patents and publications is incorporated herein by reference in its entirety for all purposes.

The preferred packaging atmosphere for fresh respiring and non-respiring fruit or vegetables often depends on the age of the fruit or vegetables and the changes (if any) which are desired. Generally, for example, the preferred O₂ content during storage of unripe fruits is lower than the preferred O₂ content during subsequent ripening at a higher temperature. This fact causes problems for both MAP and CAP. For example, in MAP, although the O₂ permability of the container generally increases with temperature (especially if it contains an atmosphere control member comprising a crystalline polymer having an appropriate melting point, as disclosed in U.S. Pat. No. 6,376,032 and International Publication No. WO 00/04787), the increase is often insufficient to avoid the need for significant compromise between the preferred atmospheres at different stages. In CAP, it is theoretically possible to monitor the packaging atmosphere and to change it as often as is necessary to maintain the preferred level of O₂ (and other gases).

But this is difficult and expensive, and often impractical. For example, U.S. Pat. No. 5,799,495 discloses a system in which biologically respiring and non-respiring material, e.g. fruit, is transported and ripened in a sealed container, and is first surrounded by a first atmosphere and thereafter by a second atmosphere, the second atmosphere containing more oxygen than the first. The atmospheres are controlled by injection of appropriate gases directly into the container.

For the transportation of berries, for example, it is typically desirable to use pallet packaging to generate a controlled or modified atmosphere inside the pallet to extend shelf-life of produce, minimize microbial growth, maintain color, and maintain freshness.

Currently, Strawberries are hand-picked in the field, placed into plastic clam shell enclosures that are then placed into cardboard trays and cardboard trays are stacked onto a wooden pallet to a height of about 100-120 inches containing about 1000 lbs. of berries. The pallet of packaged berries is transported to a cooler and the temperature reduced to about 32° F.

The cooled pallet is then placed by forklift onto a structurally robust metal support and transfer mechanism at which time jaws or clamps encircle the cardboard trays of berries, lifts up the trays as one unit and workers put a combination of cardboard and plastic sheeting onto the pallet and then the trays of berries are lowered back onto the pallet. Workers then staple or tack the about 6 inch flap of plastic sheet that extends beyond the pallet edges to the trays of berries. A pallet bag is lowered onto the pallet from above to overlap with the tacked up sheet. Tape (about 6 inch wide) is then used to seal the pallet bag to the sheet while the, for example, 1000 lb. pallet spins on the support system. A slit or hole is made in the side of the pallet bag and a probe inserted that can remove some of the inside air and replace with carbon dioxide to a target concentration. See, U.S. Pat. No. 7,770,366, which is incorporated herein by reference in its entirety.

However, there are several problems with the prior system, including:

-   -   i. The plastic sheet between the pallet and berry trays cannot         be applied in the field because the plastic sheet is often         damaged during transport leading to leaks in the bag;     -   ii. The prior system is slow and subject to human error since it         requires so many manual steps to apply the current bag system;     -   iii. The prior system requires a large footprint within the         cooler since the overall system must be structurally strong         enough to hold, move, raise, rotate and manipulate a 1000 lb.         pallet with structural strength to spare while providing a safe         work environment to works manually applying the packaging to the         pallet;     -   iv. The prior system has a high failure rate, as defined by         pallet bags not maintaining the target atmosphere due to manual         error resulting in rips, tears, leaks at the seal where the bag         and bottom sheet meet and are taped, etc. In particular the         taped seal is a source of significant leak failure;     -   v. The prior system, equipment, and slow manual process time         lead to a slow system;     -   vi. The prior system is prone to worker health issues due         toworkers bending over, stapling sheet, lifting, and other         labor-intensive involvement; and     -   vii. Without the use of the BreathWay® membrane, the current         system can develop high CO₂ levels that lead to off-odor,         off-taste and a short shelf-life.

Some of these problems are addressed using a single-bag system with the use of a designed gas permeable membrane, such as the BreathWay® membrane described in patents cited and incorporated herein by reference in their entirety and by automating the system such as in U.S. application Ser. No. 15/604,629 and the co-filed U.S. Provisional applications titled “Pallet Bag” and “Automated Process and Apparatus for Packaging Biological Materials,” which are incorporated herein by reference in their entirety.

However, in an embodiment of that system the load of biological materials (e.g., berries), is placed on a pallet wherein the pallet must be prepared with a pallet load bag that can be lifted around the load and sealed to establish the packaging environment for the materials. From the prior art methods of packaging other pallet loads of such materials, the typical approach is to manually gather the bag to place around the pallet for subsequent raising and sealing around the load of materials. This manual process is time-consuming, subject to non-repeatability errors, and prevents an automated overall packaging approach.

The embodiments of the present invention address this problem by adding critical automation to improve the speed and quality of the process, addressing the aforementioned problems.

The first area of the invention includes the following aspects.

A first aspect of the invention includes a pallet bag gathering apparatus having a plurality of roller wheels designed to advance a pallet bag onto an adjustable frame capable of duplicating the dimensions of the pallet to be used in the automated pallet bag packaging system. The apparatus can be used to gather pallet bags of any dimensions but is particularly useful when it is designed to gather and compress pallet bags with the following properties:

-   -   i. The length of the pallet bag for use in the automated         gathering apparatus may be about 50 to about 150 inches long,         preferably about 113 inches to about 120 inches long;     -   ii. The circumference of the pallet bag is from about 150 inches         to about 250 inches, preferably about 175- about 200 inches,         most preferably about 186 inches in circumference;     -   iii. The bag composition is typically polyethylene (PE),         generally low density polyethylene (LDPE) which may have         additives and features to improve durability;     -   iv. The pallet bag typically is gusseted, with the sides folded         inward;     -   v. The bags may optionally have one or more holes, for example,         about 18 inches from the top of the bag, each of the holes being         covered by an atmosphere control membrane (ACM), preferably the         patented ACMs sold by Landec Corporation under the tradename         BreatheWay, such membranes may be the same or different;     -   vi. The location of the ACM membranes is on or near the top         surface of the pallet bags is preferred and desirable to         minimize blockage from load shifting during shipment; and     -   vii. The pallet bags and ACMs are designed with dimensions to         accommodate each different type of produce due to different         respiration rates and quantities.

In a second aspect the pallet bag gathering apparatus has the following features:

-   -   i. A gathering frame that is made of a rigid material such as         metal that is from about 150 inches to about 250 inches,         preferably about 175- about 200 inches, most preferably about         186 inches in circumference and shaped to fit the pallet bag;     -   ii. The gathering frame may be adjustable to accommodate pallet         bags of different circumferences;     -   iii. The gathering frame has feed wheels that automatically         advance the bag over the frame until it is stopped by the guide         stops at the ends of the plurality of guide arms;     -   iv. The number of guide arms may vary but in one embodiment each         side has four guide arms, though two to six may be used         alternatively, said guide arms being flexibly attached to the         gathering frame wherein each guide arm has a feed wheel at one         end and a guide stop at the other end;     -   v. The guide arms are flexible with sufficient tension to secure         the gathered pallet bag to the gathering frame but flexible         enough to allow the pallet bag to pass under the guide wheel         into the gathering area;     -   vi. The gathering area is the area of the guide arm between the         feed wheel and the guide stop, wherein the area must be         sufficient to collect the entire length of the pallet bag;     -   vii. The guide wheels are controlled by a controller which may         operate manually to start when the top of the pallet bag is fed         into the guide wheels or preferably programmed to start         advancing the bag upon sensing the bag has been fed to         substantially all guide wheels and to continue until the end of         the pallet bag advances to contact the gathering frame; and     -   viii. Optionally, the gathering frame is positioned above a         pallet or a pallet is placed below the gathering frame to         transfer the gathered pallet bag to the pallet for use in the         automated pallet packaging system.

In a Prior to use the guide arms are initially in a release position wherein the guide wheels are not in contact with the gathering frame but the guide stop is in contact with the gathering frame proximate to the top portion of the gathering frame. In one embodiment the guide arm pivots at the guide stop such that the guide wheels are not in contact with the gathering frame. A pallet bag is dispensed from the bag rolls and the top opening of the pallet bag is fed under the guide wheels, at which time the guide arm is made to pivot to a position where it is in contact with the outside portion of the pallet bag, wherein the inside portion of the pallet bag is pressed against the gathering frame by the guide wheels. Said guide arms may be from about 1 foot to about 2 feet in length preferably, though the preferred length can be determined as needed to accommodate the gathered pallet bag. The guide arms have a space between the guide wheel and the guide stop that is approximately rectangular in shape with a width of approximately the diameter of the guide wheel, which may be about 3 inches to about 6 inches and a length from about 1 foot to about 2 feet. This space is used to collect the gathered pallet bag.

After the pallet bag is fed under the guide wheels, which may be automatic or manually fed, and the guide wheels are pivoted to contact the outside of the pallet bag, then gathering process can be initiated either manually or automatically by sensing the pallet bag has been fed to a point beyond the contact point of the guide wheels to the gathering frame. The guide wheels move in a direction to feed the pallet bag into the space between the guide wheel and the guide stop on the gathering frame. The gathering process in a preferred embodiment takes less than about twenty seconds, preferably less than ten seconds. When the bottom of the gathered bag is secured against the lower part of the gathering frame, the guide wheels stop either manually or automatically by sensing the resistance of the bag or by sensing the bottom of the bag against the gathering frame. To remove the gathered bag from the gathering frame the guide wheels may be pivoted away from the gathering frame such that the wheels are no longer in contact with the outside surface of the pallet bag. The gathered pallet bag may then be lowered from the gathering frame and preferably placed on a pallet in preparation for moving the pallet with the gathered pallet bag to a station of an automated pallet bag packaging system to receive a load of biological materials for packaging within the pallet bag.

Alternatively, the pallet bags may be gathered, removed and stacked for use in the automated pallet bag packaging system. Alternatively, the pallet gathering apparatus is integrated into the pallet bag packaging system such that a gathered bag is automatically deposited on a pallet for loading biological materials on such pallet, extending the pallet bag over the biological materials, and sealing the bag.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are for illustrative purposes and do not depict every embodiment of the invention.

FIG. 1 is a depiction of a top-diagonal view of the pallet bag gathering apparatus.

FIG. 2 is a depiction of a rear view of the pallet bag gathering apparatus.

FIG. 3 is a depiction of a top down view of the pallet bag gathering apparatus.

FIG. 4 is a depiction of a side view of the pallet bag gathering apparatus.

DESCRIPTION OF THE DRAWINGS

In the Summary of the Invention above and in the Detailed Description of the Invention, the Examples, and the Claims below, reference is made to particular features (including method steps) of the invention. It is to be understood that the embodiments of the invention include all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.

The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B and C can consist of (i.e. contain only) components A, Band C, or can contain not only components A, Band C but also one or more other components. Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).

Where reference is made herein to sealed packages and sealed containers, and to sealing bags and other containers containing biological materials, it is to be understood that the sealing can be, but sometimes is not, hermetic sealing, due to poor heat seal operation, poor taping or poor closure.

Conventional methods for sealing bags and other containers can conveniently be used in this invention. Such conventional methods include, for example, the use of a cable tie to seal the neck of a polymeric bag. A seal made by conventional methods often is not a hermetic seal, and has the advantage that it permits equilibration of the pressures inside and outside the bag. If the container is sealed hermetically, it will generally be desirable to include one or more pinholes in the container, to achieve such equilibration and or through appropriate choice of ACM, for example BreathWay membranes alone or in combination with other ACMs. If two Breatheway ACMs are used, for example, one can avoid the need for pinholes even when hermetically sealed.

The less complete the sealing of the container, the less the influence of the permeability of the container on the packaging atmosphere within it. Thus, even a poor seal may be sufficient, or even desirable, for example when the desired O₂ content of the packaging atmosphere lies between the O₂ content of the atmosphere surrounding the package and the O₂ content of the packaging atmosphere that would result if the seal was a hermetic seal. Under such circumstances, the sealing could be designed to permit a controlled amount of direct exchange between the packaging atmosphere and the atmosphere surrounding the container.

Pallet Bag—Generating Internal Atmospheres

The Pallet bag may be a standard thickness, for example about 2 to about 8 mil, more preferably about 3 to about 4 mil and may be composed of any plastic material, low density polyethylene (LDPE) is a preferred plastic (since by using a mechanical locking device no heat sealing is needed—but heat sealing may be applied) but any plastic monolayer, plastic laminates or multicomponent laminates or blends may be used for example, PE, PP, PET, thermoplastic elastomer, stretch plastic, Nylon, paper/plastic laminates, and the like. Other bag materials and thicknesses may be used. However, it is desirable that the upper portions of the wall material should be sufficiently flexible to be used with the mechanical seal preferably used in the pallet packaging system herein.

Suitable flexible material for the bag may be PE, PP, Nylon, polyester, recycled or repurposed plastic, low cost paper/plastic laminates, and other laminates. Preferred materials include LDPE, Linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE). Depending on the method of applying the bag over the pallet, a stretch plastic may be preferred.

In one embodiment the pallet bag material contains one or more specialty additives, including additives having one or more of the following properties: anti-microbial; anti-fungal; photobiodegradable; oxo-photobiodegradable; UV blocker; anti-drag; anti-scratch; print enhancer; anti-static; anti-fog; pro-release; and pest repellant (e.g., ant, rodent). The material may optionally contain metallic silver particles, zeolites, organic micro-particles, titanium dioxide, and silica, as well as other additives to aid in the process and promotion of packaged biological materials.

Because heat sealing may be unnecessary when using a “mechanical seal”, the pallet bag material may be selected based on cost or moisture vapor transmission rate (MVTR) properties or puncture resistance or other reasons. Integral to the pallet packaging system is the use of atmosphere control technology, for example a BREATHEWAY® membrane or microperforations as appropriate. Preferably the pallet packaging system uses a BREATHEWAY® membrane, as described in other Apio/Landec patents and patent applications, including U.S. Pat. Nos. 5,254,354; 6,376,032; 6,548,132, and 7,329,452, each of which is incorporated by reference in its entirety. Use of the membrane technology allows effective atmosphere control of oxygen and carbon dioxide for extension of shelf-life, taste, freshness, and other benefits, such as appearance.

The pallet bag/cover may optionally have a ‘valve” mechanism built into the bag that may be a one-way or two-way valve to assist in the speed and efficiency of removing the air in the bag and replacing with CO₂ which may eliminate the need to cut and then retape the bag after CO₂ injection.

The pallet bag may optionally be a custom designed bag which, when opened and placed over the pallet will have a flat top to lie smoothly over the top layer of product trays. This bag design will not leave any hanging ears, which otherwise require taping and add extra labor, cost and time. A preferred pallet bag may be designed to fit a unit load of 48″×40″ (Standard Grocery Manufacturers Association (GMA) pallet) with varying heights and will come in a roll form. Alternatively, the pallet bag may be designed for use with a sea pallet, which commonly has a size of 1200 mm×1000 mm. Alternatively, the pallet bag may be sized for a European pallet of 800 mm×1200 mm used in some parts of Europe.

These bags in a roll will allow for easy automation.

The Pallet Bags

The pallet bags, in one aspect, form part of the present invention and can be used to drive efficiency, lower costs, and to render a clean looking finished pallet with the right atmosphere. In one embodiment, a fully automated system is used from using film in the shape of a long tube that can be automatically cut to size for a custom pallet height, with the top heat sealed and holes cut over which may be placed ACM membranes, such as BreatheWay® membranes, or microperforations for atmosphere control.

FIGS. 1-4 show features of the pallet bag gathering apparatus.

Regarding FIG. 1, the depiction of the pallet bag gathering apparatus 100 shows guide arm 120 with feeder wheels 121 and guide stops 122. The guide arm 120 pivots away from the gathering frame 110 prior to feeding the pallet bag from the pallet bag rolls 150. The pallet bag rolls may be of different lengths and circumferences depending on the containers that will be packaged within the pallet bag. Controller 130 is used to program the process of feeding the pallet bag from roller 150 between the feeder wheels 121 and the gathering frame 110 to the void space between the feeder wheels 121 and the guide stops 122. The pallet bag feeder 140 may be automatically programmed to feed the pallet bag to the gathering frame 110 and may be programmed to automatically detach the pallet bag from the roll when the bottom of the bag proceeds beyond a set point.

Regarding FIG. 2, this alternative view from behind the pallet bag gathering apparatus 200 shows the controller 230 and the plurality of pallet bag rolls 250 loaded on spools for distribution therefrom to the gathering frame.

Regarding FIG. 3, this alternative view from above the pallet bag gathering apparatus 300 shows the top of the controller, the pallet bag rolls 350, the pallet bag feeder 340, the gathering frame 310 and the guide arm 120.

Regarding FIG. 4, this alternative view from the side of the pallet bag gathering apparatus 400 shows the pallet bag feeder 440, the gathering frame 410, the feeder wheels 411, and the guide stops 412.

Persons having ordinary skill in the art will recognize certain modifications, permutations, additions and sub-combinations of the embodiments described herein. It is intended herein to include all such modifications, permutations, additions and sub-combinations. 

What is claimed is:
 1. A gathering frame to gather a pallet bag: a. wherein the gathering frame is configured to receive a pallet bag; b. wherein the gathering frame circumference is adjustable; c. wherein the gathering frame has a plurality of guide arms; and d. wherein the guide arms have a plurality of feeder wheels and plurality of guide stops.
 2. The gathering frame of claim 1, wherein the gathering frame is configured to receive a pallet bag from about 150 to about 250 inches in circumference.
 3. The gathering frame of claim 1, wherein the feeder wheels advance the pallet bag into a void space between the feeder wheels and the guide stops.
 4. The gathering frame of claim 1, wherein the gathered pallet bag is fed from one or more pallet bag rolls.
 5. The gathering frame of claim 3, wherein after gathering the pallet bag in the void space between the feeder wheels and the guide stops, the guide arms pivot the feeder wheel to not contact the gathering frame and the gathered pallet bag is removed from the gathering frame and placed on a pallet for loading materials thereon.
 6. The gathering frame of claim 1, wherein the pallet bag is configured to receive an ACM.
 7. The gathering frame of claim 6, wherein the ACM comprises a crystalline polymer.
 8. The gathering frame of claim 1, wherein the thickness of the pallet bag is from about 2 to about 8 mil and composed of an ultra-low-density polyethylene (ULDPE), low-density polyethylene (LDPE), or linear-low-density polyethylene (LLDPE).
 9. The gathering frame of claim 8, wherein the pallet bag is composed of a plastic monolayer, plastic laminates, multicomponent laminates and/or blends thereof.
 10. The gathering frame of claim 1, wherein the gathering process is automated.
 11. The gathering frame of claim 1, wherein at least a portion of the gathering process is automated.
 12. The gathering frame of claim 1, wherein pallet bag comprises an additive that has anti-fungal or anti-microbial properties. 